Adjustable headwear

ABSTRACT

The disclosure relates to headwear, an example headwear including a crown and two or more overlapping panels in a rear of the crown, the overlapping panels being moveable relative to one another as a size of the crown is adjusted.

RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 62/810,325, entitled “ADJUSTABLE HEADWEAR” and filed Feb. 25, 2019. The entire contents of the above-referenced application are hereby incorporated by reference for all purposes.

BACKGROUND AND SUMMARY

Headwear may be utilized to shield a wearer from environmental hazards, such as sunlight, debris, rain, etc. Headwear may be manufactured as “fitted” (e.g., where the same headwear is manufactured having different dimensions to accommodate different wearer head sizes) or “one size fits all.” Fitted headwear may incur additional manufacturing costs over one size fits all headwear, as each size/dimension configuration may be manufactured separately, thereby decreasing batch manufacturing efficiency. One size fits all headwear may include adjustment mechanisms in order to accommodate different wearer head sizes. However, typical size adjustment mechanisms may provide a select number of discrete size options, which may not accommodate all head sizes. Size adjustment mechanisms may also be limited to only adjusting a small portion of the headwear (e.g., a headband or bottom portion of a crown of the headwear), which may not address sizing issues in other regions of the headwear and which may lead to unsightly bulging of excess material in regions of the headwear.

The present disclosure provides a new construction method and associated headwear that is configured to create maximum size adjustability so that a one size fits all style of hat is capable of fitting a wide range of wearers without the drawbacks of other sizing mechanisms described above. For example, the present disclosure describes headwear that includes overlapping panels in a rear of a crown of the headwear, which are able to be used with a wide variety of adjustment mechanisms to provide additional hat sizing flexibility. The overlapping panels of the headwear may flex outward, bound only by the length of sizing webbing or tape that is used. The new construction of headwear described herein allows for the overlapping panels to overlap more or less during associated sizing adjustments, and removes any unsightly bulging or puckering of excess material. In some examples, a dissolving thread mesh may be used to aid in breathability in the rear panels. In other examples, the rear panels may be constructed with a solid plain weave or any other material.

Examples are disclosed for headwear comprising a crown, and two or more overlapping panels in a rear of the crown, the overlapping panels being moveable relative to one another as a size of the crown is adjusted.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure may be better understood from reading the following description of non-limiting embodiments, with reference to the attached drawings, wherein below:

FIG. 1 is a front view of a hat in accordance with an example of the present disclosure.

FIG. 2 is a rear view of the hat of FIG. 1 showing adjustable sizing features of the hat.

FIG. 3 is a right side view of the hat of FIG. 1.

FIG. 4 is a left side view of the hat of FIG. 1.

FIG. 5 is a top view of the hat of FIG. 1.

FIG. 6 is a bottom view of the hat of FIG. 1.

FIG. 7 is a front view of a hat in accordance with another example of the present disclosure.

FIG. 8 is a rear view of the hat of FIG. 7 showing adjustable sizing features of the hat.

FIG. 9 is a right side view of the hat of FIG. 7.

FIG. 10 is a left side view of the hat of FIG. 7.

FIG. 11 is a top view of the hat of FIG. 7.

FIG. 12 is a bottom view of the hat of FIG. 7.

FIG. 13 is an isometric front view of the hat of FIG. 7.

FIGS. 14A-14C show example detail views of a portion of the crown of the hat of FIG. 6 in different stages as the hat is resized.

DETAILED DESCRIPTION

In adjustable headwear, a solid crown or a pony tail hole may be provided in a rear of the hat. Solid crown constructions may be formed of a solid piece of material, while constructions with a pony tail hole may be formed of a solid piece of material that includes defined edges to form the hole. In either construction, the overall circumference of the headwear and/or crown can only stretch to be the interior circumference of the hat, thereby limiting the maximum size to which the headwear may be adjusted. Furthermore, utilizing a size adjusting mechanism to effectively reduce the interior circumference of the hat for the above constructions may result in the puckering of the crown of the hat since there is nowhere for the excess material (formed by the reduction in interior circumference) to gather.

As described above, the disclosure provides for a construction of headwear in which overlapping rear crown panels are provided to increase size adjustability ranges and decrease deformation of the crown due to excess material in the crown. Examples of headwear including overlapping rear crown panels are shown in FIGS. 1-13, where FIGS. 1-6 show an example of headwear with overlapping panels used in conjunction with a ribbon-based size adjustment mechanism and FIGS. 7-13 show an example of headwear with overlapping panels used in conjunction with a buckle-based size adjustment mechanism. It is to be understood that the size adjustment mechanisms disclosed herein are exemplary in nature, and the overlapping crown panels and other features described in the disclosure may be utilized in other configurations and/or with other size adjustment mechanisms without departing from the scope of this disclosure.

FIG. 1 shows a front view of an example hat 100. Hat 100 includes a brim 102 extending from or otherwise carried by a hat body 104. Hat body 104 includes a multi-paneled crown that is configured to extend over a top of a wearer's head. In some embodiments, the crown may include a plurality of panels extending around a circumference or perimeter of the crown and intersecting at a central region (e.g., a top of the crown). Although illustrated as a crown that extends over a top of a wearer's head, it is to be understood that features of the present disclosure may also be used for hats that at least partially expose a portion of a wearer's head (e.g., a visor-type hat or other hat that includes an opening in a top portion of the crown region). In the illustrated example, the crown may include a front panel 106 and two side panels 108 a and 108 b. In other examples, the region of the crown formed by the front and side panels 106, 108 a, and 108 b may be formed of a unibody construction (e.g., a single piece of material). In the illustrated example, the front panel 106 and the side panels 108 a and 108 b may include a bottom side that curves around a circumference of the hat body. In some examples, each panel (or the entirety of the hat body/brim) may include the same type of fabric or other material. In other embodiments, one or more panels (or the hat brim) may include a different type of material than the other panels. The front panel 106 and/or the outer material of front panel 106 may be secured to the surrounding panels 108 a and 108 b via respective stitching along each side of the panel or by any other suitable securing mechanism. In some examples, the front panel 106 may be the same size as side panels 108 a and/or 108 b. In other examples, the front panel 106 may be a different size (e.g., larger or smaller) than the side panels 108 a and/or 108 b.

The hat 100 may include a size-adjusting mechanism in the form of a pair of ribbons 110, which may be attached to a rear of the hat and which may be configured to be tied to one another with a tightness that controls the size of the hat. The ribbons 110 are shown in more detail in FIG. 2.

FIG. 2 shows a rear view of hat 100 including overlapping rear panels 202 a and 202 b. For example, rear panel 202 a may pass over rear panel 202 b, at least partially obscuring rear panel 202 b. The rear panels 202 a and 202 b may include arched bottom edges that form an opening 204 in the rear of the hat. The rear panels 202 a and 202 b may overlap a proportion of one another that is greater than one half and/or that changes as the hat is resized via a sizing mechanism (e.g., to any level of overlap). Each rear panel 202 a and 202 b may have a triangular shape with a first edge that abuts and/or is coupled to a first side panel of the crown, a second edge that abuts and/or is coupled to a second (e.g., opposing) side panel of the crown, and a third edge that is curved and at least partially forms the opening 204 in the rear of the hat. The third edge of the rear panel 202 a may cross the third edge of the rear panel 202 b at a central region, and the intersection point of the two rear panels may change as the hat is resized via the sizing mechanism.

An elastic band 206 (shown and described in more detail below with respect to FIG. 6) may be provided to connect the rear panels to one another and/or may form a bottom rear portion of the circumference of the crown. The elastic band 206 may include an elastic material that is able to stretch as the crown size is increased and retract as the crown size is decreased. In some examples, the elastic band 206 may be coupled directly to the rear crown panels (e.g., a first terminating end of the elastic band 206 may be coupled directly to the rear panel 202 a and a second terminating end of the elastic band 206 opposite the first terminating end may be coupled directly to the rear panel 202 b). In other examples, the elastic band 206 may be coupled to a headband or other inner crown surface. The elastic band 206 may be coupled to the crown directly or via a further elastic coupling mechanism (e.g., a coupling mechanism with a different elasticity than the elastic band 206).

Ribbons 110 may be coupled to the rear crown panels and/or another portion of the crown. For example, as illustrated, each ribbon is coupled to a seam between a respective one of the rear panels 202 a and 202 b and a respective side panel 108 a and 108 b. Ribbons 110 may be tied to one another with a tightness that controls the crown sizing for the hat 100. For example, as the ribbons 110 are tied together with increasing tightness, the rear panels 202 a and 202 b may be pulled closer to one another to overlap further (e.g., rear panel 202 b may be tucked further under rear panel 202 a, decreasing a size of the opening 204). As the ribbons 110 are loosened from one another, the rear panels 202 a and 202 b may be pulled away from each other to overlap less (e.g., rear panel 202 b may be pulled from under rear panel 202 a and may be more exposed, increasing a size of the opening 204). In this way, the panels may allow for increased size ranges and smoother crown appearance for different sizing relative to constructions using a solid or single rear crown panel.

The rear panels 202 a and 202 b may be formed of a different material than other panels of the crown and/or other material of the hat 100. For example, the rear panels 202 a and 202 b may include a mesh material and/or an elastomeric material (e.g., a material that has a higher elasticity than other material of the crown) in order to provide breathability and/or additional flexibility in sizing the hat 100.

In the illustrated example, the brim 102 is a crescent shape that includes ends that terminate into the crown of the hat. Accordingly, the brim 102 may provide increased flexibility in hat resizing compared to other configurations, as the brim may be expandable/retractable with the crown circumference to accommodate different wearer head sizes.

As shown by the arrows in FIG. 2, the configuration of the hat 100 including the rear panels 202 a and 202 b enables the crown of the hat to be resized in multiple regions in order to conform to a wearer's head size and shape and reduce the gathering of excess material. For example, the size of region R1, which corresponds to a top portion (e.g., an uppermost portion) of the crown of the hat, may be adjusted via movement of the panel 202 a in the directions indicated by arrow A1 and via movement of the panel 202 b in the directions indicated by arrow A2. The movement of the rear panels 202 a and 202 b may be facilitated by user adjustment of the ribbons 110, which may also directly adjust the size of region R2, which corresponds to a bottom portion of the crown of the hat. The ribbons 110 may be tied together via a knot, and a tightening or loosing of the knot may control movement of the ribbons 110 in the directions indicated by arrow A3. For example, as the ribbons are tied more tightly, the terminating ends of the ribbons, which are respectively coupled to a seam of at least one of the rear panels 202 a and 202 b, are pulled more closely together, reducing the size of the crown in region R2. Such tightening of the ribbons also causes the rear panels 202 a and 202 b to move toward one another (e.g., panel 202 a moves in the upward/right direction in the illustrated example, and panel 202 b moves in the upward/left direction in the illustrated example), reducing the size of the crown in region R1 and reducing the buildup of excess material which would otherwise result from tightening one region of the crown (e.g., region R2) without correspondingly tightening another region of the crown (e.g., region R1). In an inverse manner, as the ribbons 110 are loosened, the terminating ends of the ribbons are allowed to move away from one another, increasing the size of the crown in region R2. Such loosening of the ribbons also causes the rear panels 202 a and 202 b to move away from one another (e.g., panel 202 a moves in the downward/left direction in the illustrated example, and panel 202 b moves in the downward/right direction in the illustrated example), increasing the size of the crown in region R1.

Elastic band 206 provides for controlling a size adjustment via movement in the directions indicated by arrow A4 in a further region R3, which corresponds to a lowermost region of the crown (e.g., a headband area of the crown) and a topmost region of the brim. As the ribbons 110 are tightened, the elastic band 206 may constrict to assist in pulling together the edges of the brim and crown at the opening 204, thereby tightening the lowermost region of the crown. As the ribbons 110 are loosened, the elastic band 206 may expand to allow the edges of the brim and crown at the opening 204 to pull away from each other, thereby loosening the lowermost region of the crown. The elastic band 206 may be biased to pull the edges of the brim and crown at the opening 204 together in order to maintain a snug fit of the hat on a wearer's head.

FIGS. 3 and 4 show right and left side views of the hat 100, respectively. As illustrated, the side panels 108 a and 108 b have a similar shape to front panel 106. FIG. 5 shows a top view of the hat 100. As illustrated, the crown is formed of front panel 106, side panels 108 a and 108 b, and rear panels 202 a and 202 b. Front panel 106, side panels 108 a and 108 b, and rear panel 202 a are illustrated as being joined at a top center point of the crown. FIG. 6, which shows a bottom/interior view of the hat 100, illustrates that rear panel 202 b is also joined to the other panels at an underside of the top center point. As further illustrated in FIG. 6, elastic band 206 bridges a gap between terminating edges of the brim 102 and spans between terminating edges of the rear panels 202 a and 202 b.

A further illustration of example resizing of the crown of hat 100 is shown in FIGS. 14A-14C. FIG. 14A shows a portion of the bottom/interior view of hat 100 from FIG. 6 including the rear panels 202 a and 202 b, as well as the ribbons 110 and the elastic band 206. FIG. 14B shows the portion of the bottom/interior view of FIG. 14A resized to decrease an overall crown sizing (as indicated by the arrows representing inward movement of the rear panels 202 a and 202 b and tightening of the ribbons 110). As shown, the triangle-like shape formed by the overlapping rear panels is decreased in size as the rear panels are adjusted as described above with respect to FIG. 2. For example, the overall size of the triangle-like shape formed by the overlapping rear panels may decrease in size, such that a spacing between edges of the triangle-like shape (including the edges formed by the side edges of the rear panels that are coupled to side panels 108 a and 108 b, respectively) decreases in size. Likewise, the elastic band 206 is decreased in size to ensure a snug fit with the decreased crown width. In some examples, a curvature of the third edge of one or both of the rear panels 202 a and 202 b may change in response to the size adjustment (e.g., increasing a degree of curvature with decreasing size of the crown).

FIG. 14C shows the portion of the bottom/interior view of FIG. 14A resized to increase the overall crown sizing (as indicated by the arrow representing outward movement of the rear panels 202 a and 202 b and loosening of the ribbons 110). As shown, the triangle-like shape formed by the overlapping rear panels is increased in size as the rear panels are adjusted as described above with respect to FIG. 2. For example, the overall size of the triangle-like shape formed by the overlapping rear panels may increase in size, such that a spacing between edges of the triangle-like shape (including the edges formed by the side edges of the rear panels that are coupled to side panels 108 a and 108 b, respectively) increases in size. Likewise, the elastic band 206 is increased in size to accommodate the larger crown width. In some examples, a curvature of the third edge of one or both of the rear panels 202 a and 202 b may change in response to the size adjustment (e.g., decreasing a degree of curvature with increasing size of the crown).

FIG. 7 shows a front view of another example hat 700 that includes rear crossing panels for size adjustment flexibility. Hat 700 includes a brim 702 extending from or otherwise carried by a hat body 704. Hat body 704 includes a multi-paneled crown that is configured to extend over a top of a wearer's head. In some embodiments, the crown may include a plurality of panels extending around a circumference or perimeter of the crown and intersecting at a central region (e.g., a top of the crown). In the illustrated example, the crown may include a front panel 706 and two side panels 708 a and 708 b. In other examples, the region of the crown formed by the front and side panels 706, 708 a, and 708 b may be formed of a unibody construction (e.g., a single piece of material). In the illustrated example, the front panel 706 and the side panels 708 a and 708 b may include a bottom side that curves around a circumference of the hat body. In some examples, each panel (or the entirety of the hat body/brim) may include the same type of fabric or other material. In other embodiments, one or more panels (or the hat brim) may include a different type of material than the other panels. The front panel 706 and/or the outer material of front panel 706 may be secured to the surrounding panels 708 a and 708 b via respective stitching along each side of the panel or by any other suitable securing mechanism. In some examples, the front panel 706 may be the same size as side panels 708 a and/or 708 b. In other examples, the front panel 706 may be a different size (e.g., larger or smaller) than the side panels 708 a and/or 708 b. An outer headband 710 may extend around at least a portion of the crown circumference. Outer headband 710 may be included in addition to an inner headband disposed in an interior of the crown (not shown in FIG. 7). A rear cape 712 may extend from the brim 702 to protect a wearer's neck from environmental elements (e.g., sun/rain).

FIG. 8 shows a rear view of the hat 700. As illustrated, the hat 700 may include a size-adjusting mechanism 801 including a buckle and strap for adjusting a circumference of the crown of the hat. The rear of the hat 700 further includes overlapping rear panels 802 a and 802 b. For example, rear panel 802 a may pass over rear panel 802 b, at least partially obscuring rear panel 802 b. The rear panels 802 a and 802 b may include arched bottom edges that form an opening 804 in the rear of the hat. An elastic band 806 may be provided to connect the rear panels to one another and/or may form a bottom rear portion of the circumference of the crown. The elastic band 806 may include an elastic material that is able to stretch as the crown size is increased and retract as the crown size is decreased. In some examples, the elastic band 806 may be coupled directly to the rear crown panels. In other examples, the elastic band 806 may be coupled to a headband or other inner crown surface. The elastic band 806 may be coupled to the crown directly or via a further elastic coupling mechanism (e.g., a coupling mechanism with a different elasticity than the elastic band 806).

Size-adjusting mechanism 801 may be coupled to the rear crown panels and/or another portion of the crown. For example, as illustrated, opposing terminating ends of the size-adjusting mechanism 801 are coupled to a seam between a respective one of the rear panels 802 a and 802 b and a respective side panel 708 a and 708 b. A strap of the size-adjusting mechanism 801 may be pulled through a buckle of the size-adjusting mechanism to control the crown sizing for the hat 700. For example, as the strap is pulled further through the buckle, the rear panels 802 a and 202 b may be pulled closer to one another to overlap further (e.g., rear panel 802 b may be tucked further under rear panel 802 a, decreasing a size of the opening 804). As the strap is pulled out of the buckle (e.g., in an opposite direction from the tightening action), the rear panels 802 a and 802 b may be pulled away from each other to overlap less (e.g., rear panel 802 b may be pulled from under rear panel 802 a and may be more exposed, increasing a size of the opening 804). In this way, the panels may allow for increased size ranges and smoother crown appearance for different sizing relative to constructions using a solid or single rear crown panel.

The rear panels 802 a and 802 b may be formed of a different material than other panels of the crown and/or other material of the hat 700, similarly to rear panels 202 a and 202 b as described above.

FIGS. 9 and 10 show right and left side views of the hat 700, respectively. The side panels 708 a and 708 b have a similar shape and/or size to front panel 706 in some examples, whereas in other examples, one or more of the panels may be larger than one or more of the other panels. FIG. 11 shows a top view of the hat 700. As illustrated, the crown is formed of front panel 706, side panels 708 a and 708 b, and rear panels 802 a and 802 b. Front panel 706, side panels 708 a and 708 b, and rear panel 802 a are illustrated as being joined at a top center point of the crown. FIG. 12, which shows a bottom/interior view of the hat 700, illustrates that rear panel 802 b is also joined to the other panels at an underside of the top center point. As further illustrated in FIG. 12, elastic band 806 bridges a gap between terminating edges of the brim 702 and spans between terminating edges of the rear panels 802 a and 802 b. FIG. 13 shows an isometric front view of the hat 700, illustrating an example shape of the brim 702 and positioning of crown panels in this example. As shown, the brim 702 terminates into the rear cape 712 at an approximate mid-point of the side of the crown.

The features described herein may be provided in various combinations of headwear examples to provide a flexible, robust, and functional hat that performs well in any environment and stands up to heavy use. Although wide-brimmed hats are illustrated and described, it is to be understood that any one or more of the features described herein may be included in any suitable style of hat, including, without limitation, a ball cap, a charter hat, a sun fedora, a boonie hat, a capotain, a gat, a hardee hat, a homburg, a panama, a sombrero, a sun visor, a brimless-hat (e.g., a beanie or toque), a top hat, a legionnaire hat, a flap hat, and/or any other suitable head covering.

The description of embodiments has been presented for purposes of illustration and description. Suitable modifications and variations to the embodiments may be performed in light of the above description. The described headwear features are exemplary in nature, and may include additional elements and/or omit elements. The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various headwear and configurations, and other features, functions, and/or properties disclosed.

As used in this application, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural of said elements or steps, unless such exclusion is stated. Furthermore, references to “one embodiment” or “one example” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. The terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements or a particular positional order on their objects. The following claims particularly point out subject matter from the above disclosure that is regarded as novel and non-obvious. 

1. Headwear comprising: a crown; and at least two overlapping panels including a first panel and a second panel overlapping one another in a rear of the crown, each of the first panel and the second panel being triangular in shape and having a respective curved bottom edge, the first panel crossing the second panel at a central region of the curved bottom edge of the second panel, the first and second panels being moveable relative to one another to resize multiple regions of the crown.
 2. The headwear of claim 1, wherein the first and second panels being moveable relative to one another to resize multiple regions of the crown includes the first and second panels being movable to any level of overlap between the first panel and the second panel.
 3. The headwear of claim 1, wherein at least in a closed position, the first panel overlaps more than half of the second panel.
 4. The headwear of claim 1, further comprising a size-adjusting mechanism coupled to the crown, the size-adjusting mechanism controlling a respective circumference of each of a plurality of regions of the crown.
 5. The headwear of claim 4, wherein the size-adjusting mechanism comprises a buckle and a strap, a first terminating end of the strap being coupled directly to the crown at a first side of an opening formed between the overlapping panels in the rear of the crown and a second terminating end of the strap passing through the buckle, the buckle being coupled to the crown at a second side of the opening, opposite the first side of the opening.
 6. The headwear of claim 5, wherein the first terminating end of the strap is coupled to a first panel of the two or more overlapping panels and wherein the buckle is coupled to a second panel of the two or more overlapping panels.
 7. The headwear of claim 4, wherein the size-adjusting mechanism comprises a first ribbon and a second ribbon, the first ribbon being coupled directly to the crown at a first side of an opening formed between the overlapping panels in the rear of the crown, and the second ribbon being directed coupled to the crown at a second side of the opening, opposite the first side of the opening.
 8. The headwear of claim 7, wherein the first ribbon is coupled to a first panel of the two or more overlapping panels, and the second ribbon is coupled to a second panel of the two or more overlapping panels.
 9. The headwear of claim 1, further comprising a rear cape extending from a bottom edge of the crown and/or from a hat brim.
 10. Headwear comprising: a crown; at least two overlapping panels including a first panel and a second panel overlapping one another in a rear of the crown, each of the first panel and the second panel being triangular in shape and having a respective curved bottom edge, the first panel crossing the second panel at a central region of the curved bottom edge of the second panel, the first and second panels being moveable relative to one another to resize multiple regions of the crown; and an elastic band extending between the two or more overlapping panels at a bottom edge of each of the two or more overlapping panels along a circumference of the crown.
 11. The headwear of claim 10, wherein a first terminating end of the elastic band is directly coupled to a first panel of the two or more overlapping panels and a second terminating end of the elastic band, opposite the first terminating end, is directed coupled to a second panel of the two or more overlapping panels.
 12. The headwear of claim 10, wherein the elastic band is directly coupled to an interior of the crown.
 13. Headwear comprising: a crown; at least two overlapping panels including a first panel and a second panel overlapping one another in a rear of the crown, each of the first panel and the second panel being triangular in shape and having a respective curved bottom edge, the first panel crossing the second panel at a central region of the curved bottom edge of the second panel, the first and second panels being moveable relative to one another to resize multiple regions of the crown; and a hat brim extending from a bottom edge of the crown.
 14. The headwear of claim 13, wherein the hat brim is crescent shaped and wherein opposing terminating ends of the crescent shape of the hat brim each terminate into the crown at a respective different side of an opening between the two or more overlapping panels.
 15. The headwear of claim 13, wherein the hat brim is semi-circular, and wherein the hat brim terminates into a rear cape that extends from the crown.
 16. The headwear of claim 13, wherein the two or more overlapping panels are formed of a mesh material.
 17. The headwear of claim 13, wherein the two or more overlapping panels include an elastomeric material.
 18. The headwear of claim 13, wherein the two or more overlapping panels each include a bottom edge having an arched shape.
 19. The headwear of claim 13, wherein the two or more overlapping panels are mirror symmetric to one another.
 20. The headwear of claim 13, wherein an outermost panel of the two or more overlapping panels is larger than an innermost panel of the two or more overlapping panels. 